JP2009533240A - Vehicle trim - Google Patents

Abstract

  A method for forming a trim member of a vehicle is disclosed. The method includes the steps of setting a decorative element in a mold, molding a substrate, bonding the substrate to the decorative element, and demolding a vehicle trim member. The step of molding the substrate includes the steps of introducing a first liquid resin material (for example, isocyanate) and a second liquid resin material (polyol) into a mixing head to form a mixed resin material, and placing the mixed resin material in a mold. And introducing towards the decorative element. The decorative element can be composed of aluminum, alloy, thermoplastic resin, thermosetting resin, elastomer, metal, wood, leather, or fiber.

Description

This application claims the benefit of US Provisional Patent Application No. 60 / 790,420, filed Apr. 7, 2006. This provisional application is incorporated herein by reference.

  The present disclosure relates to a trim member for a vehicle interior. The present disclosure particularly relates to a vehicle molded by reaction injection molding a urethane material toward a decorative element such as metal, wood, leather, fiber, cork or other material used for applications in the vehicle interior. The present invention relates to a trim member for decoration.

  It is known to provide a decorative trim member that can be used for the interior of a vehicle. Such a known decorative trim member is a rigid plastic substrate that is pre-formed using a crimping operation, heat staking operation, fasteners, or other physical attachment techniques, for example, a decorative element such as aluminum. It can manufacture by attaching to. It is also known to produce such known decorative trim members by injection molding plastic towards the decorative trim. However, such known techniques are expensive to manufacture and do not realize certain advantageous features (and / or combinations of features). For example, crimping, heat staking and other mounting operations require processing machine investment and further quality inspection. The injection molded substrate will shrink away from the decorative element. In both cases, the trim element will be separated from the substrate. It is also known to use urethane reaction injection molded products as foam for cushions and as the “skin” of the exterior surface. However, it is not known to use this material and method as a structural element for carrying trim parts on a vehicle.

  Providing decorative trim members that are inexpensive, reliable and widely applicable decorative trim members that avoid the above-mentioned problems and other problems represents a significant advance in the art. Will do.

  Disclosed is a method for molding a vehicle trim member, the method comprising: setting the decorative element in a mold; molding the substrate; bonding the substrate to the decorative element; and demolding the vehicle trim member. Is done. The step of molding the substrate includes a step of introducing a first liquid resin material (for example, isocyanate) and a second liquid resin material (for example, polyol) into a mixing head to form a mixed resin material, and the mixed resin material in the mold. And introducing towards the decorative element. The decorative element can be composed of aluminum, multiple metals, alloys, thermoplastic resins, thermosetting resins, elastomers, wood, leather, or fibers.

  There is also provided a vehicle trim member including a decorative element and a substrate coupled to the decorative element. The substrate is held in place by the end folded inside the decorative element. The substrate can be made of urethane resin.

  The present disclosure further relates to various features and combinations of features shown and described in the disclosed embodiments. Other ways in which the objectives and features of the disclosed embodiments can be achieved are described in the following specification or will become apparent to those skilled in the art after reading this specification. Such other methods are considered to be within the scope of the disclosed embodiments if they are within the scope of the appended claims.

  Before describing in detail some examples and alternative embodiments of a vehicle decorative trim, this disclosure provides details of the constituent elements referred to in the following description or represented in the drawings and It should be understood that the arrangement is not limited. The decorative trim can be in other implementations, or can be implemented or implemented in various ways. Also, the wording and terminology used herein are for illustrative purposes and should not be considered as limiting. For example, the components of the disclosed embodiment will be represented as a vehicle trim member designed for a door, but the features of the disclosed embodiment have very wide applicability. For example, the design of a vehicle trim member is also suitable for other examples where a decorative element is to be added to another structure, such as a structure in any diverse environment such as commercial, industrial, office, home or education. Applicable. Furthermore, the size of the various components and the size of the decorative trim member can vary greatly. It is also important to note that the terms “decorative”, “trim”, and “substrate” are intended as broad terms and are not limiting terms. These components can be used in any of a variety of products and arrangements and are not intended to be limited in use for vehicle application.

  Referring to FIG. 1, a vehicle interior 4 is shown with a door 6 and some instrument panels 8. The door and instrument panel each include a decorative trim member 10 that is coupled to a structural portion of the door or instrument panel. Doors and instrument panels are shown by way of example and not limitation. Those of ordinary skill in the art reviewing this disclosure will recognize the decorative trim members in any of a variety of areas within the vehicle room other than doors and instrument panels, including but not limited to ceilings, visors, pillars, luggage parts, seats, consoles, etc. You will recognize that you can wear it on. The decorative trim member generally includes at least a decorative element 12, a substrate 14 and a mounting tab 16.

  The decorative element 12 typically includes an outer shell having an end 18 bent inward (see FIG. 4A). The inwardly folded end 18 can be at an angle of about 90 ° to the adjacent portion of the outer shell. Alternatively, the inwardly folded ends can be at any of various angles with respect to adjacent portions of the outer shell, eliminating the need for joining, depending on the capabilities of the processing machine and the needs of the producer. . The inwardly folded end is not necessarily required for all embodiments, but if an inwardly folded end is included to create a mechanical lock between the cured substrate and the trim, The need to join in some way between the substrate and trim is eliminated and / or minimized.

  In the preferred embodiment shown in FIGS. 4A and 4B, the decorative element 12 includes a plurality of aperture holes (eg, holes, apertures). Aluminum is a preferred material for making decorative elements. However, other materials can be used including thermoplastic resins, thermosetting resins, elastomers, metals, wood, leather, fibers, or any other variety of materials desired for use as a decorative element.

  The decorative element 12 is coupled (e.g., gripped, clamped) to the substrate 14 by molding substantially across the entire surface of the substrate 14 and / or with the end 18 folded inside the decorative element 12. Restricted, encased, constrained, retained, fixed, etc.). In the embodiment shown in FIGS. 4A and 4B, the plastic material used for the substrate 14 forms a mechanical bond with at least a portion of the plurality of apertures in the decorative element 12.

  The mounting tab 16 is insert-molded to provide a structure for mounting the decorative trim member 10 to a door, an instrument panel, a ceiling portion, another vehicle interior portion, or the like. According to one example, the mounting tab 16 is metal, but in other embodiments it can be any of a variety of materials (eg, plastic, etc.). The mounting tab 16 can be “L” shaped, “U” shaped, curved, arched, straight, or any of a variety of shapes and forms, depending on the desired mounting and engagement configuration.

  According to one embodiment, the substrate 14 is a structural member and is molded from a plastic material. According to one preferred embodiment, the substrate 14 is shaped by a reaction injection molding (RIM) operation. RIM is a preferred substrate molding method because it is injected at low pressure and low temperature, a processing machine is inexpensive, can be applied to an insert processing system (for example, a mounting tab), and uses a material that is cheaper than injection molding. In addition, the injection-molded substrate may move away from the decorative element 12 due to the shrinkage of the plastic that may generate a roaring, squeaking or rattling noise of the decorative trim member 10 when the plastic is cooled and solidified. is there. According to a particularly preferred embodiment, the substrate 14 is composed of a reactive polyurethane or PUR molded from a prepolymer urethane resin. Unlike known RIM urethane applications (using urethane as a foam for cushions and as the “skin” of the exterior surface), RIM urethane forms a structural element that carries trim parts on a vehicle. According to another embodiment, the substrate 14 includes other urethane resins and systems for RIM.

  FIG. 7 illustrates a method 20 of forming a decorative trim member 10 according to a preferred embodiment. In this process, a decorative part or element 12 (for example, metal, wood, leather, etc.) is received (step 22) and a processing tool is prepared (for example, application of a release agent, cleaning of the processing tool, etc.) (step 24). . The decorative element 12 is loaded into the working tool (step 26). Inserts such as mounting tabs 18 can also be set into the processing tool (step 28). The processing tool is closed (step 30), and if necessary, the mixing head is set on the processing tool (step 31). As an alternative, the processing tool is closed after urethane injection (ie the “open injection” method). Subsequently, a plastic resin (for example, PUR) is injected (step 32) to form the substrate 14, and air and / or carbon dioxide is exhausted from the forming tool (step 33). The plastic resin is cured (partially or completely) (step 34), the working tool is opened (step 35), and the decorative trim member 10 is removed / demolded (step 36). If necessary, the decorative trim member 10 is deburred and / or cleaned (step 37). Subsequently, the decorative trim member can be mounted or assembled in the vehicle compartment or mounted to other components in the vehicle cabin using mounting tabs 18 if provided (step 38).

  5 and 6A-6D are schematic views of the manufacturer of the decorative trim member 10. In accordance with a preferred embodiment, a reaction injection molding (“RIM”) method for molding a decorative trim member 10 is shown as an example. It is desirable to use the RIM method to control the wall thickness of the end and the raised portion of the protrusion. As shown in FIG. 5, a mold 40 having a cavity 42 is prepared for receiving an injection component used for molding a decorative trim member 10 (for example, a substrate). As shown in FIG. 6A, the mold 40a includes an inner surface or mold surface 46 (eg, the cavity side) that is configured to be connected in a sealing relationship to the core surface 44 of the core 49, and the cavity 42 (See FIG. 6C). According to one embodiment, the core surface 44 includes a shaped portion 48 that has the shape of a protrusion (see FIG. 6A) (see FIG. 6A). The recess 45 of the shape portion 48 forms a required contour (for example, a structural member, a rib, or a protrusion) in the substrate 14. The core 49 (including the core surface 44, the shape portion 48, and the depression 45) provides a surface morphology and decoration as the material injected into the mold cavity 42 assumes the shape defined by the shape portion 48 and the surface 44. The overall shape of the trim member 10 is defined. For purposes of illustration, FIG. 6A shows an example of a shaped portion 48 of the core surface 44. Unlike known RIM urethane applications (using urethane as a foam for cushions and as the “skin” of the exterior surface), RIM urethane forms a structural element that carries trim parts on a vehicle.

  The RIM process uses polyurethane for the production of molded parts. The starting materials for polyurethane are two liquid components-an isocyanate and a polyol. The isocyanate material can be either an aromatic material (generally photolabile) or an aliphatic material (generally photostable), or a combination of aromatic and aliphatic materials. If an aromatic material is used, a paint or other coating can be used to shield it from light. In some embodiments, depending on how the polyurethane RIM system is configured, the part molded thereby can be a foam or solid, flexible to extremely rigid Can vary up to.

  The RIM method is a chemical reaction between two liquid components stored in separate supply tanks 50, 52 that are temperature controlled as shown in FIG. Referring to FIG. 5, isocyanate and polyol are fed from these tanks 50, 52 to mixing head 64 through separate feed lines 54, 56 to metering devices 58, 60. In one embodiment, when liquid injection into the mold 40 begins, the valve of the mixing head 64 is opened. Liquid reactants flow into the chamber of the mixing head 64 at a predetermined pressure (eg, below 3,000 psi) and are mixed by high velocity impact. The liquid flows from the mixing chamber into the mold 40 at approximately atmospheric pressure. Within the mold 40, the liquid undergoes an exothermic chemical reaction, thereby forming a polyurethane polymer within the mold 40. In various embodiments, the cycle time varies depending on part size and reaction conditions. In many cases, the material can be injected into the mold 40 and cured within about 90 seconds. Subsequently, demolding is performed.

  6A-6D show in detail how the molded part is molded in the cavity. Referring to FIG. 6A, a release agent spray 66 is applied in and / or to the cavity 40a. As shown in FIG. 6A, a release agent spray 66 is applied to the mold surface 46. The release agent spray 66 is intended to easily remove the decorative trim member from the mold after demolding. Referring to FIG. 6B, a paint spray 68 can be applied in and / or to the cavity 40a. A paint spray 68 can also be applied to the mold surface 46 as shown in FIG. 6B. Paint spray 68 provides light stability to aromatic-based materials (isocyanates) and, in certain embodiments (not shown), provides appropriate coloration and appearance characteristics for finished products (eg, decorative trim members). Give. Release agent spray 66 and / or paint spray 68 can be applied manually or by a spray device. In other various embodiments, no release agent spray and / or paint spray is applied in and / or to the cavity. Referring to FIG. 6C, the core 49 is disposed above the mold 40 a and a cavity 42 is formed between the mold surface 46 and the core surface 44. An injection region or portion 70 is provided through core 49 to allow injection of material 72 into cavity 42. Referring to FIG. 6D, material 72 has been injected into the cavity 42 between the core surface 44 of the core 49 and the mold surface 46 of the mold 40a. According to one embodiment, the injection material 72 is injected at an angle in the range of about 80-100 degrees relative to the mold surface 46. In a preferred embodiment, the injection material 72 is injected at an angle of about 90 ° relative to the cavity 40a. After being injected into the cavity 42, the injected material 72 is cured and demolded after a period of time that varies with several factors such as temperature, component material properties, and the like. In one embodiment, the injection material 72 is cured and demolded at a temperature in excess of 100 ° F. In various embodiments, the cavity surface (for A surface formation) and the core surface (for B surface formation) are nickel outer shells (eg, electroplating, nickel vacuum plating, etc.), steel (machining, etc.), aluminum (machining) , Casting, etc.), spray metal alloys and the like. In another embodiment, the work tool material can be "soft", such as silicone, for use in low volume applications.

  It is also important to note that the configuration and arrangement of the elements of the decorative trim member shown in the preferred embodiment and other examples is for example purposes only. Although the present disclosure has described in detail a few examples of current vehicle decorative trims, those of ordinary skill in the art who have reviewed the disclosure will substantially depart from the novel teachings and advantages of the subject matter referred to. Many changes can be easily made without leaving (eg changes in size, dimensions, structure, shape and ratio of various elements, parameter values, mounting arrangements, material usage, color, orientation, etc.) I will admit. For example, an element shown as being integrally formed may be composed of multiple parts, or an element shown as multiple parts may be integrally formed, the interface manipulation may be reversed or otherwise changed, the structure and It is possible to change the length or width of the members or couplings or other elements of the system, change the nature or number of adjustment positions provided between the elements (eg the number of engagement slots or the engagement Depending on the size of the slot or the type of engagement). It should be noted that the system elements and / or assemblies may be constructed from any of a variety of materials that provide sufficient strength or durability in any of a variety of colors, textures, and combinations. Accordingly, it is intended to encompass all such modifications. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the preferred and other examples without departing from the essence of the present disclosure.

It is an external view inside a vehicle compartment including a trim member for decoration. It is a top view or a front view of a decorative trim member according to one embodiment. FIG. 3 is a bottom view or rear / rear view of the decorative trim member of FIG. 2. 4A is a partial view of the decorative trim member of FIG. 3, and FIG. 4B is a partial view of the decorative trim member of FIG. It is a model representation of the manufacturing apparatus of the trim member for decoration by the reaction injection molding based on an Example. Figure 2 shows various stages of a process for manufacturing a decorative trim member by reaction injection molding according to an example. It is a schematic flowchart of the process of the manufacturing method of the trim member for decoration by an Example.

Claims (14)

A method for forming a trim member of a vehicle,
Setting the decoration elements in the mold;
Introducing a first liquid resin material and a second liquid resin material into a mixing head to form a mixed resin material;
Introducing the mixed resin material into a mold and towards the decorative element;
Forming a substrate and joining the substrate to the decorative element;
Removing the trim member of the vehicle;
Including methods.   The method of claim 1, wherein the first liquid resin material is an isocyanate.   The method of claim 2, wherein the second liquid resin material is a polyol.   The method of claim 1, wherein the substrate is a urethane resin.   The method of claim 4, wherein the step comprises a reaction injection molding process.   The method of claim 1, further comprising adding a mounting tab to the mold prior to introducing the mixed resin material.   The said decorative element is selected from the group comprising at least one of aluminum, multiple metals, alloys, thermoplastics, thermosetting resins, elastomers, metals, wood, leather, or fibers, or combinations thereof. The method according to 1.   The method of claim 1, wherein the substrate is held in place by bonding to the decorative element.   The method of claim 1, wherein the substrate is held in place by gripping on the decorative element with an inwardly folded end. Decoration elements,
A substrate coupled to the decorative element, the substrate maintained in place by an end folded inside the decorative element;
A vehicle trim member.   The vehicle trim member according to claim 1, wherein the substrate includes a resin material.   The vehicle trim member according to claim 2, wherein the resin material is urethane resin.   2. The decorative element is selected from the group comprising at least one of aluminum, multiple metals, alloys, thermoplastics, thermosetting resins, elastomers, metals, wood, leather, fibers, and combinations thereof. The vehicle trim member according to claim 1.   The vehicle trim member according to claim 1, comprising a mounting tab coupled to the decorative element and the substrate.

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